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从0到13台3D打印机:

远铸智能如何助力Terrestrial X 打造北美高性能打印中心?

一家刚成立一年的制造公司,如何在高要求行业实现增材制造的跨越式突破?

“我之前完全不了解3D打印,只知道我们需要它。” ——Matt Jensen,Terrestrial X 首席运营,直言不讳地回忆起公司的起点。

加拿大公司 Terrestrial X 成立于2023年,是一家专注于高性能工业制造解决方案的年轻企业。他们从零起步,在一年内搭建起一座1万平方英尺的3D打印中心,服务对象涵盖能源、航空航天和电气行业。

而支撑这一快速发展的,正是 远铸智能 提供的工业级FDM打印设备 —— FUNMAT PRO 310 NEOFUNMAT PRO 610HT

“这些机器三个月连续运行,几乎没有停机。”

Terrestrial X 按照材料与任务类型对设备进行了功能分区:

  • FUNMAT PRO 310 NEO 主要承担碳纤维增强PC、ESD安全材料、尼龙等材料的小批量生产任务其 IDEX 双喷头结构在复杂几何支撑、精细结构成型方面表现出色,支持支撑材料与模型材料的分离打印,优化打印质量与后处理效率。
  • FUNMAT PRO 610HT 应用于PEEK、PEKK等高温塑料的终端零件打印,适配封闭腔体+高温热端的生产场景,特别适用于对耐热、耐化学性与尺寸稳定性要求极高的航空航天应用

Matt 回忆道,团队早期曾尝试使用其他打印设备进行高温材料的打印,但在 PEEK 等极限材料方面始终存在稳定性不足的问题。

之前使用的打印机没办法打印PEEK...我是说,根本不行

正因如此,他们决定升级至 远铸智能 的 FUNMAT PRO 610HT,以满足对高温材料的一致性和工业级打印环境的需求。

在工厂打印中心的产线配置中,Terrestrial X 建立了由 FUNMAT PRO 310 NEO、FUNMAT PRO 410 和 FUNMAT PRO 610HT 共同构成的组合方案,Matt 表示这是他们未来持续扩大生产能力的关键策略:

未来我们将持续使用这组设备组合

这套配置不仅支持多材料、多任务并行处理,也具备高度扩展性,为后续生产能力的提升提供了坚实基础。

三人运营13台设备的秘诀

虽然打印中心已扩展至十几台设备,Terrestrial X 的运营团队仍然保持高效精简仅由三人负责整个打印中心的日常运维。这背后,离不开 远铸智能 设备在软硬件集成方面的优势:

  • 统一的软件管理体系:通过 INTAMSUITE 切片软件可集中管理任务、参数、材料切换;
  • 材料与文件可复用:大幅降低不同设备间的调试与培训成本;
  • 低维护、高稳定性:设备长期运行无需频繁人工干预,支持高密度任务排布。

Terrestrial X 目前已经实现使用 远铸智能 设备进行直接客户交付的终端件小批量生产,交付流程高效,并且早已赚回了购买机器的成本。

Matt 表示,设备的“工业友好性”是他们能将增材制造从原型走向终端零件交付的关键。

为什么选择远铸智能?

  • Matt 在访谈中提到,他们曾对多个品牌的高温打印设备进行对比评估,最终选择 远铸智能,主要出于以下几方面考量:

    1. 稳定性与可复制性

    设备部署后几乎即插即用,可迅速整合到既有流程中,不必进行大量定制调试。

    1. 材料兼容性强

    FUNMAT PRO 310 NEO 支持多种工程塑料,包括碳纤维增强 PC、ESD 级尼龙等,材料切换快速,打印参数一致性高。

    1. 适合规模部署

    通过 INTAMSUITE 和统一材料参数库,方便不同设备统一调度、复制工艺,实现批量化生产。

    1. 经济性出色

    在同类工业级高温设备中,远铸智能 以合理的采购成本和可靠性能,为中小企业提供了进入生产级增材制造的理想路径。

从0到系统交付,一家打印中心的进阶之路

Matt总结道:

我们原本只是从0开始学,现在已经在谈论系统级的交付能力了。”

Terrestrial X 用一年时间构建起一个兼具功能件与终端件交付能力的打印中心,完成了从探索到量产的转变。他们的故事也证明了一点:

不必先成为专家,只要选对了合作伙伴,也能快速实现跨越式成长。

远铸智能 将持续为全球制造企业提供高性能、高可复制性的工业级 FFF 打印解决方案,助力客户在各自领域实现真正的生产转型。

New Wheel Package

Enhanced aerodynamics and kinematics improve the car's handling and speed, crucial for better track performance.
Carbon Rim and New Brake Caliper
Lighter and more durable, these components ensure superior control and reliability, enhancing overall performance and safety.
Carbon Rim and New Brake Caliper
The E0711-11 EVO includes 99 3D-printed parts, reducing weight and production costs, showcasing the team's commitment to advanced manufacturing.
Weight Reduction
High-performance polymers and 3D printing have reduced the EVO's weight by over half a kilo, enhancing speed and agility on the track.

After thorough research and benchmarking, WEERG chose INTAMSYS as their supplier. The INTAMSYS FUNMAT PRO 410 met all their requirements with features like a heated chamber, dual heated nozzles, and a heated filament chamber.

INTAMSYS offered one single solution that got it all:

  • A robust printer with a sleek aesthetic finish, heated chamber, dual heated nozzles, and heated filament chamber.
  • Free and user-friendly software with incorporated printing settings (Click and Print experience) for a wide range of materials (from PA12-CF to PEEK).
  • Reliable support, and most importantly for WEERG, honesty and a true partnership.
WEERG also appreciated the user-friendly software with incorporated printing settings and the reliable support from INTAMSYS.

They went for INTAMSYS and received their FUNMAT PRO 610HT in June 2021. Since the purchase of the printer, they have printed many prototypes, some end-use parts, and from time to time jigs/fixtures and tooling parts.

As the printer has a high chamber temperature (up to 300°C), it also means that all temperatures in between are covered too. 4D Concepts has printed out parts of many plastic types; from PLA, ABS, PC, to PAEK, PEEK, PEI 9085/1010.

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4D Concepts – prototype of a temperature-resistant pulley made of glass-fiber reinforced PEEK (PEEK-GF).

 

We accompany our customers in a professional manner throughout the entire project - from planning and design to the prototype or the production of a complete series. Combining our 3D printing processes with conventional component processing, post-processing and surface refinement of the prototypes, small series or even a trade fair exhibit is our daily business. Since the company was founded in 1995, our experienced team in Gross-Gerau has made a name for itself well beyond the borders of the Rhine-Main area. We are one of the leading service providers for everything to do with 3D printing and have more than satisfied customers from a wide variety of industries - from the automotive and consumer goods industries to mechanical engineering and companies from the medical technology sector.

Alex Di Maglie
Managing Director,  4D Concepts

We were looking for printers that can print high-performance materials and run 24/7 on our production floor. INTAMSYS offered a robust printer, a nice aesthetic finish, and a true partnership.

Matteo
Founder & CEO, WEERG

The application of high-end filaments made of high-performance plastics such as PEI is not new to the field of 3D Printing. However, it requires both, a wide range of skills (materials and production) and the appropriate machinery.

Thanks to its large-format 3D printer from INTAMSYS, 4D Concepts can now process a wide range of high-end plastics with excellent thermal and mechanical properties for prototyping. Parts are out of PEI 9085.
 

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The INTAMSYS FUNMAT PRO 410 has been a performant and reliable tool since day one. It allows us to process high-performance polymers that enable our customers to innovate with them in highly loaded, thermally challenging, and metal replacement applications. It gives us the confidence that is needed to print 24/7 unattended with long print jobs of 100+ hours. It redefines what can be achieved with FDM technology.

Fabio Trotti
3D R&D Manager, WEERG

  • INTAMSYS FUNMAT PRO 410

    3D PRINTER

    FUNMAT PRO 410

  • 图片3

    COST-EFFECTIVE

    Print Larger, Print More

  • 4D-Concepts-0222-3-1024x938

    OPEN

    Open-Sourced Filaments

Greent team

Click DOWNLOAD to Get the Full Customer Story

Our Solution

INTAMSYS has sponsored the GreenTeam with a FUNMAT HT 3D printer, INTAM™ filaments, and consultation services. The 3D printed parts from INTAMSYS are used in various subsystems of the car, including the battery system, braking system, and power electronics.

  • intamsys-funmat-ht

    3D PRINTER

    FUNMAT HT

  • intamsys-funmat-ht-printing

    COST EFFICIENCY

    Lower Cost, Shorter Lead Times

  • materials

    MATERIAL SUPERIORITY

    Versatile INTAM™ Polymers

Tank Holder

The tank holder is a new part in this year´s racing car. The part is printed on the FUNMAT PRO 610HT with the material choice of ABS. For the driverless disciplines, the team uses pressurized air to activate the brakes in an emergency. This year, they changed the concept of how pressurized air is stored, which required a new mounting solution. The tank holder is designed to solve this challenge.

Tank holder
Flap Ribs (2)

Flap Ribs

Other 3D printed parts, using the FUNMAT PRO 610HT and PC material, are the flap ribs that play a crucial role in the construction of the car’s side wing. These ribs are glued into the carbon-fiber shells and incorporate threaded inserts for attaching the wing to the chassis.

While the team has used these ribs for years, they have redesigned for this season to accommodate changes in the aerodynamic shape of the wings. Using INTAMSUITE™ NEO and the 3D printing technology, they conducted topology optimization to achieve the lightest possible geometry, resulting in an organic shape that would not be possible to manufacture by milling.


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